Saab 96 Sport brake calipers – checking the condition

We decided to check out the condition of the original brake calipers for the Saab 96 Sport. I wanted to know if they can be restored or if I need to buy new ones on the Trollhättan visit next summer.

The pistons and fittings on the Sport calipers were pretty much rusted solid.

We used electrolysis to remove the worst rust.

Most of the rust removed, but the pistons are still completely stuck.

Heat gun helped remove some of the fittings.

To remove the pistons we made a special tool: Grease gun nipple fitting.

A two stroke brake hose is attached to the nipple-fitting.

The grease gun gives enough pressure to remove even the more stubborn pistons.

The custom grease gun fitting was a big help in removing the pistons. We didn’t have a nipple that fit the thread on the caliper (it’s an inch-size thread and we only had millimeter-size nipples). Of course if you have a nipple that fits the caliper directly there’s no need to make a separate connecting piece.

As it turned out the brake cylinders are in very good condition and I only need new pistons and seals.